Novel Design of an Integrated Pulp Mill Biorefinery for the ...

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equires lower temperatures to run the digester, and temperatures remain constant throughout the process. A second chemical process is called the sulfite process and operates at a lower temperature than the kraft process, produces a brighter paper, yet forms shorter fibers [8]. These shorter fibers require the resulting papers to be thicker in order to retain strength. As a result, less paper can be made per ton of wood. The sulfite process uses burnt sulfur mixed with a basic solution as the treating fluid. Black liquor is still produced, but more difficult to recover. Energy estimates for this process are 4.2 GJ/ton of pulp and 572 kWh/ton of pulp electricity. The sulfite process is only used for specialty pulp used to make very smooth paper [14]. The active alkali ingredient in most pulp mills today is sodium hydroxide (NaOH). It requires 400 kg pro ton of pulp to appropriately process the pulp. NaOH is often purchased by the plants, running a total of $165 per ton in 2001. The total energy cost of making this alkaline requires 2.85MWh/ton NaOH [19]. In the conventional, open bleaching process using a chlorine chemical for pulp bleaching, the alkaline extraction steps require 20-60 kg NaOH per ton of pulp [20]. Modern pulp mills today require 15 kg of white liquor during treatment per ton of chips coming in [21]. 2.1.2.3 Semi-chemical Pulping Semi-chemical pulping is not a very widely used process in modern day pulp mills. It is mainly used for hardwood pulping because of the short fibers it contains. These shorter strands form a more opaque, smoother and denser paper [8]. 5.3 GJ per ton and 505 kWh per ton are the energy demands for this process [13]. 2.1.3 Chemical Recovery Chemical pulping results in the formation of an energy dense byproduct called black liquor. Black liquor is used in current paper mills to create energy to fuel the entire plant. The inorganics that are contained in black liquor that cannot be used for energy are collected and reformed so that they can be used in the kraft process again. The first stage towards recovering the chemicals given off during the digestion stage to is to remove the water. When black liquor is collected from the cooking stage, around 15 volume percent is usable black liquor solids. In order to use the black liquor solids efficiently, the solution going to the gasifier or recovery boiler must be 80 volume percent solids. Typical plants use a series of two evaporators known as multiple effect evaporators (MEE) and direct contact evaporators (DCE). MEEs uses steam to concentrate the mixture via evaporation to 50% black liquor solids. The DCEs are used following this stage by using the exhaust gasses of the recovery boiler to further reduce the mixture to the 80% solids concentration. The energy consumed by the evaporators is around 4.4 GJ/ton of pulp. [14] Canadian Office of Energy estimates 3.1 GJ/ADt and 30 kWh/ADt are used for a modern kraft pulp mill. [22] In a recovery boiler, the organic compounds that exist in the black liquor are then oxidized in order to produce heat. The smelt from the recovery boiler is mixed with a weak white liquor solution to form green liquor. This green liquor is primarily made up of sodium carbonate (Na2CO3) and sodium sulfide (Na2S). Approximately 1.1 GJ per ton of pulp and 58 kWh/per ton of pulp is required for auxiliary power for a furnace. When the black liquor is oxidized, approximately 15 GJ per ton of pulp is produced. [16] Black liquor when it is gasified, or burned in a recovery boiler, will result in the collection of inorganic sulfur in the bottom of the reactor. During that process a mixture of 12
sodium sulfide and sodium carbonate forms at the bottom of the typical recovery boiler. The contents of the aqueous solution are sodium carbonate, 90-100 g/L, sodium sulfide, 20-50 g/L, and sodium hydroxide, 15-25 g/L. If the white liquor rises above 35% sulfidity it is considered poisonous to the pulp, and not useful. 2.1.4 Extending the Delignification Process Oxygen delignification, kraft pulping additives, and alternative pulping chemistry can further extend the delignification process and reduce the use of bleaching chemicals (Pulliam, 1995). The best digestion practices will only remove approximately 90 percent of the lignin in the pulp. Oxygen delignification helps reduce fading and increases strength of the paper. It is applied between the pulping and bleaching stages. It enables total chlorine free bleaching (TCF) to be possible. During delignification, the pulp is heated to around 100 degrees Celsius at 1 MPa for an hour. Fifteen kilograms of oxygen and 30 kilograms of sodium hydroxide are used in this process A one stage system will remove fifty percent of the remaining lignin, while the two stage system will remove seventy percent. [23] Ozone bleaching is also a powerful oxidizer and is applied after the oxygen delignification process. From three to ten kilograms of ozone is required to complete ozone bleaching. The most economical way to produce ozone is through the oxygen coming out of the air separation unit. ECF or TCF sequences containing ozone offer the lowest bleaching costs. [24] A more experimental practice introduced recently is using a pressurized peroxide stage. Increasing pressure, temperature, and perhaps a little oxygen has greatly increased the brightening power and efficiency of the peroxide stage. The pressurized peroxide stage utilized for final brightening requires 100 degrees Celsius at 0.5 MPa for 2 hours. The residence time required to reach a given brightness is also reduced to approximately 20% of that required in a conventional peroxide bleach tower. [24] 2.1.5 Bleaching After the pulping stage, there is still a significant lignin which is closely bonded with the pulp. This requires a series of bleaching stages to remove the lignin because the lignin adds undesirable weakness and color to the paper. Before environmental controls kicked into full gear, pure chlorine (Cl2) was used to bleach the pulp. Due to environmental concerns a whole host of chemicals including ozone, hydrogen peroxide, enzymes, and chlorine dioxide have proven to be viable substitutes. The main counter-current washing systems in kraft pulp bleaching involve three different wash water circulation systems: direct counter-current, jump-stage and/or split flow washing. Each of these stages employs alkaline or acid washes. For example, a five stage wash could look like this, (DC)(EO)DED, with the D stages using acidic solution and stages with E using an alkaline solution. Acidic solution in the past was elemental chlorine, but now used chlorine dioxide or other substitutes. Alkaline solution active chemicals are sodium hydroxide and sodium sulfide [25]. Washing systems are used to separate the white liquor from the pulp-water suspension during the bleaching phase. Free liquor exists in suspension surrounding the wood chips and is relatively simple to remove. The “fiber phase” which includes wood fibers and white liquor entrained in those fibers offers a more difficult challenge, but is required in order to make the paper efficient. Entrained liquor in the fiber phase can only be removed by diffusion or capillary 13
Page 1 and 2: Novel Design of an Integrated Pulp
Page 3 and 4: Table of Contents List of Figures .
Page 5 and 6: List of Figures Figure 1: Price of
Page 7 and 8: 1 Introduction The global transport
Page 9 and 10: 2 Background 2.1 Pulp Mill Backgrou
Page 11: 2.1.2.2 Chemical Pulping The most c
Page 15 and 16: process described in the section on
Page 17 and 18: 2.2.1 Low-Temperature Black Liquor
Page 19 and 20: Figure 2: Chemrec gasification proc
Page 21 and 22: Table 3: Average syngas composition
Page 23 and 24: DME than that could be obtained fro
Page 25 and 26: U.S. Patent[58] and European Patent
Page 27 and 28: Figure 4: Topsøe gas phase technol
Page 29 and 30: DME Workshop, Japan (Sept. 7, 2000)
Page 31 and 32: 2.4.1. Fischer-Tropsch Reactors The
Page 33 and 34: kpH 2 pCO Cobalt rate = 2 (2.4.1) (
Page 35 and 36: invention of Fischer-Tropsch in the
Page 37 and 38: Table 7: hydrocarbons and associate
Page 39 and 40: 3 Process Design 3.1 Pulp Mill 3.1.
Page 41 and 42: carbonate is fired in a lime kiln t
Page 43 and 44: lost and the pulp that provides tha
Page 45 and 46: Table 16: General operating paramet
Page 47 and 48: Table 19: Ash analysis of Pittsburg
Page 49 and 50: Table 22: Experimental syngas compo
Page 51 and 52: 3.2.5 Process Options and Flexibili
Page 53 and 54: Nitrogen compounds Nitrogen from th
Page 55 and 56: 3.3.2.3 Reactors A single-step gas
Page 57 and 58: Table 27: FT-diesel fuel synthesis
Page 59 and 60: 3.5.2 Power Generation Process Desi
Page 61 and 62: Figure 21: Schematic of biorefinery
Page 63 and 64:
ar) reacts with the fuel in the com
Page 65 and 66:
Figure 25showed the detailed energy
Page 67 and 68:
4. Design Summary The DME design an
Page 69 and 70:
Figure 27: Mass and energy flow of
Page 71 and 72:
References 1. Åhman, M., G. Modig,
Page 73 and 74:
42. R.A. Peascoe, J.R.K., C.R. Hubb
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PerformanceSimulation. 2006, Prince
Page 77 and 78:
Appendix Appendix A MP Steam Demand
Page 79 and 80:
Appendix B: Composite Fuel Blend to
Page 81 and 82:
DME Density = 0.67 kg/L (at 20 °C)
Page 83 and 84:
Air Separation Unit Requirements Ba
Page 85 and 86:
Purge gas: CO conversion is 60%, 40
Page 87 and 88:
Appendix D: FTD Synthesis Two diffe
Page 89 and 90:
Table D.3: The hydrocarbon product
Page 91 and 92:
Figure D.3 Mass and energy balance
Page 93 and 94:
Table D.3 Mass and energy balance o
Page 95 and 96:
Appendix E: Heat and Power Generati
Page 97 and 98:
Energy H2O absorbed MW 46.71 Using
Page 99 and 100:
Combustion 2CO+O2→ 2CO2 + 566 kJ/
Page 101 and 102:
Specific Heat (cp) b kJ/kgK 1.072 E
Page 103 and 104:
Specific Heat of Steam (cp) kJ/kgK
Page 105:
Appendix F: Concept Map 105
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